Railroad tie and method for making same

ABSTRACT

Thermoplastic polymers, rubbery polymeric components and reinforcing fillers are mixed and heated to a range of 380° F. to 440° F. The resulting mixture is then fed into a Banbury mixer, with the resulting mixture fed into a diverter feeding two molds. The velocity of the piston of each mold being filled is controlled to thereby control the density of the molded product along its length. As each mold is filled, it is deposited in a cool water bath (50° F.-60° F.) while the next mold is being filled. The molds are sequentially transferred to an air cooling rack to complete the process. A texture, generally comprising indentations perpendicular to the longitudinal axis on the molded object, provides a frictional surface between the railway crosstie and the ballast beneath the crosstie.

BACKGROUND ON THE INVENTION

[0001] This invention relates, generally, to molded products made fromthermo plastic materials, and specifically, to composite railroad tiesand methods for making same. The invention relates more specifically tonew and improved railroad ties which will last longer in hot, humidenvironments and to methods for making such railroad ties.

PRIOR ART

[0002] It is well known to make railroad ties from thermoplasticmaterials, for example, as described in U.S. Pat. No. 5,799,870 to JohnC. Bayer.

[0003] It is also known to make railway ties from sand and recycledthermoplastic containers, for example, as described in U.S. Pat. No.5,055,350 to Charles W. Neefe.

[0004] It is also well known to make railroad ties from recycled tirefragments, for example as described in U.S. Pat. No. 5,238,734.

[0005] Moreover, it is well known to make porous flexible pipes fromthermoplastic materials and thermoset materials, for example, asdescribed in U.S. Pat. No. 5,366,365 to Henry W. Sullivan, et al.

[0006] It is also well known to make sheet products from thermoplasticmaterial combined with granular scrap material, for example, oldautomobile tires, as described in U.S. Pat. No. 4,970,043 to Rosetta C.Doan, as well as in U.S. Pat. No. 5,733,943, also to Rosetta C. Doan.

[0007] Moreover it is known to make railroad ties from combinations ofpolymeric components combined with a rubbery polymeric componentobtained from disposed tires, such as is described in U.S. Pat. No.5,886,078 to Henry W. Sullivan, et al.

[0008] In addition, it is known to make elongated cylindrical moldshaving an internal sliding piston which allows the molten plastic to beintroduced into the mold which produces an elongated plastic body havingthe tube imbedded therein.

[0009] The prior art also includes U.S. Pat. No. 4,824,627 to Floyd V.Hammer, and U.S. Pat. No. 4,191,522 to James E. Turner which relate tovarious molded plastic products and extruding machines for manufacturingextruded products.

[0010] The prior art also includes U.S. Pat. Nos. 5,507,473 to Floyd V.Hammer et al; 4,028,288 to James E. Turner and 5,951,712 to JeromeCampbell.

[0011] A common element running through most if not all of the abovereferenced prior art patents is the use of using shredded rubberproducts in the finished product, such as used automobile and trucktires.

[0012] However, the prior art taken individually and in combinationfails to provide the solution to manufacturing processes for makingreliable railroad ties, or to the composition of the railroad tiesthemselves.

[0013] Specifically, the prior art fails to provide methods or apparatuswhich have the time efficiencies necessary to manufacture and supplyrailroad ties to the railroad industry.

OBJECTS OF THE INVENTION

[0014] It is therefore the primary object of the present invention,generally, to provide new and improved molded products made fromthermoplastic materials, and specifically, to provide new and improvedrail road ties, and to methods for making the same.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Referring now to FIG. 1, there is illustrated a top plan view ofan extruded rail road tie fabricated in accordance with the presentinvention.

[0016]FIG. 2 illustrates a diagramatic view of one of the molds used inaccordance with the present invention;

[0017]FIG. 3 illustrates, in somewhat more detail, the mold according toFIG. 2 but having in addition thereto a diverter for allowing theextruded materials to be diverted from one mold to the other inaccordance with the present invention;

[0018]FIG. 4 illustrates diagramatically the use of a diverter placedbetween two molds to be filled with extruded materials in accordancewith the principles of the present invention;

[0019]FIG. 5 illustrates diagramatically a cooling table which is usedto cool the extruded rail road ties as a part of the manufacturingprocess in accordance with the present invention;

[0020]FIG. 6 illustrates a system in accordance with the presentinvention which can be used to mix the materials which will be found inthe finished product and which will be used to feed the extrusion systemin accordance with the present invention;

[0021]FIGS. 7, 7a and 8 illustrate flow charts showing the processaccording to the invention for molding, externally cooling andextracting the extruded rail road ties in accordance with the presentinvention;

[0022]FIGS. 9, 10 and 11 illustrate, diagramatically, the extractorassembly which is used in accordance with the present invention whichenables the rail road ties to be extracted from the overall assemblyafter being cooled in a cold water bath and then be moved into the aircooling process used in accordance with the present invention; and

[0023]FIG. 12 illustrates in an elevated pictorial view an apparatuswhich can be used to provide texturing of an object in accordance withan embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE PRESENTINVENTION

[0024] In the drawings, similar reference characters denote similarelements throughout the several views. Referring now to FIG. 1, a topplan view, the present invention comprises, an extruded object 9, forexample, a railroad tie which typically measures between 8.5 and 9.0feet long, and having a side 16, first end 12 and a second end 14.

[0025] In the preferred embodiment, the extruded object 9, having a side16, a first end 12 and a second end 14 are comprised of wastethermoplastic, rubbery materials and strengthening materials, eachcomprising from about 4-55% of the composite mixture, as describedhereinafter in more detail with respect to FIG. 6.

[0026] In FIG. 2, mold 20 has a mold sidewall 22, a first mold end 24, asecond mold end 26, a rod housing 28, a rod 30, a piston 32, a moldinner surface 34, an elongated, toothed plate 36, a plurality of bolts38, an input port 40 and an external access port 42.

[0027] Input port 40 is located in the first mold end 24. The input port40 releasably attaches to the diverter valve 76 illustrated in FIG. 4.The piston 32 in FIG. 2 is affixed to an end of rod 30. Piston 32movably seals mold inner surface 34. The toothed plate 36 extends thelength of rod 30 and is affixed, preferably, to the lower surface of therod 30. Rod housing 28 has an external access port 42 for accessing theelongated, toothed plate 36 affixed to the rod 30.

[0028] A pair of attachment (lifting) handles 44 are located on or nearthe top surface of the mold 20 and may take any number of forms. Forexample, the handles 44 may be U-shaped, and the opening in each suchhandle may be transverse to the longitudinal axis of the mold 20, or theopening in each such handle may be co-axial with a line parallel to thelongitudinal axis of the mold 20. When the mold 20 is totally filledwith the extruded material, a pair of hoisting units (not shown) areconnected to the handles 44, respectively and the mold 20 is firstlifted vertically, for example, 1-2 feet. The hoist units are then movedhorizontally to place mold 20 wherever desired, for example, over andinto the cold water bath described hereinafter, by releasing each hoistunit from each of the handles 44, respectively. Preferably, each suchrelease is accomplished by pneumatic pressure to remove the hoist unitfrom the interior of the respective handle 44.

[0029] In FIG. 3, mold 20 is positioned in diverter 50, by guide arms52, and is locked into first station 66 of FIG. 4, at mold injector 54,by mold lock 56. Mold lock is actuated by pneumatic cylinder 62. Whenmold 20 is full, rod 30 actuates switch 64, causing diverter 50 toswitch from causing the thermoplastic mixture to flow into the firstmold at position 1 to a second, identical mold at position 2. After mold20 is filled, mold cutoff 60 is actuated by pneumatic piston 58.

[0030] In FIG. 2, input port 40, is located in the first mold end 24,input port 40 is sealably positioned at mold injector 54 as shown inFIG. 3, piston 32 is affixed to an end of rod 30, piston 32 movablyseals mold inner surface 34, toothed plate 36 extends the length of rod30 and is affixed to the lower surface of the rod 30, rod housing 28 hasan external access port 42 for accessing the toothed plate 36 affixed tothe rod 30.

[0031] In FIG. 3, there is illustrated a mold 20, a rod 30, a piston 32,a toothed plate 36, a toothed plate access port 42, a diverter 50, guidearms 52, a mold input port door 53, a mold injector 54, a mold inputport opener/closer 56, a pneumatic piston 58, a mixture overflow cutoff60, a mold input door actuating unit 62, a sensor 64, a diverter stationone (66), a diverter station two (68), a caliper 82, a brake pad 84, adisc 86, a connecting rod 88 and a gear 90 positioned to mesh with thetoothed plate 36.

[0032] In FIG. 3, mold 20 is positioned in diverter 50, at station one(66). Positioning is facilitated by guide arms 52, and is locked intofirst station (66), at mold injector 54, by mold port opener/closer 56.Mold input port door 53 is actuated by mold input door actuating unit62, as mold 20 is filled by mixture being forced into mold 20 throughmold injector 54. Mixture contacts plate 31, shown in FIG. 4, as piston31 is forced through and along the length of mold 20. Rod 30 is forcedto move out of the mold 20, as toothed plate 36 is fixedly attached torod 30. Gear 90 contacts toothed plate 36 through toothed plate accessport 42. Rod 30 and toothed plate 36 are forced past gear 90 which is incontact with plate 36. Gear 90 is forced to rotate. As gear 90 rotates,connecting rod 88, fixedly attached to gear 90, is also forced torotate. As connecting rod 88 rotates, disc 86, fixedly attached toconnecting rod 88, is forced to rotate. Frictional force to resist therotation of disc 86 is applied to disc 86 through brake pad 84 bycaliper 82. As mold 20 reaches capacity, rod 30 actuates sensor 64,causing diverter valve 76, shown in FIG. 4, to stop the thermoplasticmixture flowing into the mold 10 at filling station one (66), and tobegin to flow into the mold 20 positioned at filling station two (68),after mold 20 is mixture overflow cutoff 60 is actuated by pneumaticpiston 58. Mold input port opener/closer 56 closes mold input port door53. Mold 20 is removed from filling station one (66). Mixture overflowin mold injector 54 is removed by mixture overflow cutoff 60.

[0033] In the operation of the gear 90 and toothed plate 36 assembly,the density of the material in a given mold is varied, or made constantby controlling the braking mechanism comprised of the brake pad 84against the disc 86. Because the effective length of the mold increasesas the piston 32 is pushed through the mold, the density of the moldedmaterial will decrease as a function of the distance through which thepiston 32 moves, assuming a constant velocity of the piston 32.

[0034] If a uniform density of the molded product is desired, thevelocity of the piston can be continuously decreased by applying brakepressure at a continuously increasing rate. The brake can be appliedmanually (by hand or foot), or can be applied through the use of aprogrammed computer in conjunction with a mechanical arm or lever.

[0035] Likewise, if various combinations of density are desired alongthe length of the molded product, the brake pressure can be varied toachieve such a result. As but one example, a railway cross tie can bemade to have a uniform density along its length, or the product can havea relatively high density at its two end portions and a lower density inits middle portion, or any combination desired merely by controlling thebraking sequence with the gear 90 and the toothed plate 36, asdetermined by the application of the brake pad 84 to the disc 86.

[0036] In FIG. 4, diverter valve 76, activated by switch 64 of FIG. 3,switches from causing the thermoplastic mixture to flow through thepiping 78 and out through the mold injectors 54in first to the moldinjectors 54, station 66, in second station 68.

[0037] In FIG. 5, cooling table 100, table surface 110, support members108, conveyer 102, large conveyer rollers 106, small conveyer rollers112 and table dropoff 104 provide an apparatus for the air cooling ofthe extruded product 10.

[0038] In FIG. 5, table surface 110 is supported by support members 108.Table dropoff 104 is formed by one section of the table surface 110being vertically offset (lower) in relation to the preceding section ofthe table 100 as the conveyer 102 travels across the table 100. Dropoff104 is arranged such that as an object passes over dropoff 104 theobject will turn from one side to another side as it drops from onesection of the table surface 110 to another vertically offset section ofthe table surface 110. Conveyer 102 is directed along the table surface110 by large conveyer rollers 106 with additional guidance past tabledropoffs 104 by the small conveyer rollers 112.

[0039] Referring now to FIG. 6, there is illustrated an isometric,pictorial view of a system 200 for mixing and feeding the materials tothe extrusion molds in accordance with the present invention.

[0040] The system 200 includes a housing 202 supported above the floor204 by a plurality of legs, which may include the two legs 206 and 208,and which may include four or more legs. The housing 202 includes aflooring 210 upon which workman may walk to facilitate loading thebeginning materials into the opening 212.

[0041] It should be appreciated that the preferred embodiment of thepresent invention contemplates that the composite material which makesup the railroad ties in accordance with the invention requires that theproduct be able to withstand high temperatures, high humidity and theweight of the railroad passing along the rails which are mounted on suchrailroad ties. The preferred embodiment of the composite railroad tiehas the following components: A mixture of

[0042] from about 4% to about 55% of a thermoplastic polymer,

[0043] from about 4% to about 55% of a rubbery polymeric component; and,

[0044] from about 4% to about 55% of a reinforcing filler.

[0045] The process for forming a new product can be accomplished bymixing:

[0046] from about 4% to about 55% of a thermoplastic polymer,

[0047] from about 4% to about 55% of a rubbery polymeric component; and,

[0048] from about 4% to about 55% of a reinforcing filler;

[0049] Preferably, the thermoplastic polymer is comprised of at leastone of the materials selected from the group of materials consistingessentially of recycled polyolefins, recycled bucket resin, recycleddrum resin, densified film, recycled grocery bags, electric wirecoating, and recycled bottle resin or any combination thereof.

[0050] Moreover, the rubbery component is preferably comprised of atleast one of the materials selected from the group of materialsconsisting essentially of crumb rubber, automotive fluff, tire beltfluff, carpet backing, rubber backing and recycled circuit boards or anycombination thereof.

[0051] Finally, the reinforcing filler is preferably comprised of atleast one of the materials selected from the group of materialsconsisting essentially of carbon black, fly ash, mica, fiberglass,arregonite, crushed concrete, sand and crushed glass or any combinationthereof.

[0052] In combination the materials each comprise from about 4% to 55%of the mixture. Also, in combination, the thermoplastic polymer andrubbery components comprise at least 20% of the mixture.

[0053] A mixing compartment (not illustrated) is located within thehousing 202 in FIG. 6 to receive the materials through the opening 212.The mixing compartment contains various combinations, as needed, ofrollers, stirring paddles, heaters, etc. to ensure the melting of thematerials, as well as the mixing of such materials. The finished productdesigned to exit the mixing compartment and the housing 202 typicallyhas a desired temperature in the range of 380° F.-440° F., preferably atemperature of 405° F. It should be appreciated that by the use ofpressure and friction, the temperature of the mixture can be maintainedin this desirable range, but if desired, the temperature can also bemaintained through the use of an auxiliary heater.

[0054] When the materials have been thoroughly mixed and heated asdesired, a trap door (not illustrated) is opened, and the bulk material214, resembling a bale of hay in size and structure, is dropped onto aconveyor belt 216, a belt traveling up the sloped ramp as defined by theconveyor belt and the arrow 217. Upon reaching the top of the conveyorbelt 216, the batch of mixed material 214 is dumped through the opening218 into the housing 220.

[0055] The housing 220 contains a conventional Banbury mixer. The mixingof rubber stock and the mixing of plastic stock in Banbury mixers isquite well known by those skilled in the art. The Banbury mixer is namedfor its inventor, Mr. Banbury. A typical Banbury mixer is a large,internal mixer, similar to a doughnut mixer, with two rotors revolvingin opposite directions and at different speeds in a water-cooledchamber. Various chemicals and materials are added to the Banbury mixerthrough a conveyor at the top of the machine, to mix up a batch ofstock.

[0056] In mixing a batch of stock in a Banbury mixer, the materials areforced between the rotors, and also between the walls of the Banbury andthe rotors, by a lid operated by a hydraulic ram. While the heat causedby the pressure of the hydraulic ram and by friction tends to maintainthe temperature of the mixed material in the desired range of 380°F.-440° F., one or more heaters can be added to the system as desired.

[0057] Once a batch of material has been mixed in the Banbury mixerlocated in the housing 220, a door is opened at the bottom of the mixerto allow the material to enter the piping 80 and the diverter 76, alsoillustrated in FIG. 4.

[0058] A Banbury mixer has been described in the literature as being abatch-type mixing machine named after its inventor which has been widelyused in the rubber industry since 1920 for high-volume production. Itwill also accept plastic molding powders. Its chief feature is anenclosed barrel-shaped chamber in which two rotors with oppositelycurved contours rotate rapidly on a horizontal axis, first masticatingthe rubber and then efficiently incorporating the dry ingredients. Bothsteam and water jacketing are provided. Batches may be up to 1000 lb. Aplunger at the entrance port rides on top of the batch to furnish enoughpressure for proper mixing. A hydraulically operated discharge gate islocated below the mixing chamber.

[0059] Although the system of FIG. 6 contemplates dropping the bale 214of material from the mixer system 200 onto its conveyor belt 216 totransport the bale 214 to the Banbury mixer in housing 220, analternative embodiment would have the Banbury mixer located below thetrap door of the housing 202 to allow the bale 214 to drop into theopening 218 and eliminate the need for the conveyor belt 216. Thus,alternative embodiments of the system 200 will by obvious to thoseskilled in the art, following a reading of this specification and itsaccompanying drawings.

[0060] In FIG. 7, is a flowchart showing the process for molding,externally cooling and extracting a mixture to become an extrudedobject. S10 is the mixing step where the thermoplastic, rubber andstrengtheners are combined and mixed. The mixing process throughpressure and friction heats the combination to a range of 380 Fahrenheitto 440 degrees Fahrenheit, preferably to 405 degrees Fahrenheit. Aconveyer carries the mixture from S10 to S12. In S12 the mixture is putinto an extruder to further mix the mixture and force the mixture into amold. From S12 the mixture is forced through a heated pipe into S14. S14is a bypass valve from which the mixture may be removed from the processin the event of any unforeseen circumstances. From S14 the mixture flowsthrough a heated pipe to S16. S16 is a diverter, which has a full moldsensor, S17, to detect when the mold in either fill station 1 or fillstation 2 is full. When the mold in fill station 1 or 2 is full, S16,the diverter, directs a valve to shut off the flow of material from thefull mold in either fill station 1 or 2 and direct the flow of themixture into the empty mold in the adjacent fill station. Once a mold isfull the mold is removed from either fill station 1 or 2 and placed inS18, the cooling bath. S18, the cooling bath is preferably maintained atfrom about 50 degrees F. to about 60 degrees F. At S22 the mold istransported from one end of the bath to the other, transit time being atleast 30 minutes to allow the exterior of the mixture to cool tofacilitate removal from the mold. At S24 the full mold is removed fromthe cooling bath. At S26 the full mold, externally cooled, is removed tostorage at Station 4. At S28 the full mold is removed from storage atstation 4 to the extraction station, station 3. At S30, the extractionstation, the door latch pin on the mold is pushed up from the bottomallowing the pneumatic door opener to open the door on the mold.

[0061] Once the door is open pressure is applied to the rod extendingfrom the rear of the mold, pushing the piston inside the mold, in turnpushing the now externally cooled mixture, which has formed an extrudedobject, partially out of the mold. At S32 the extruded object is grabbedby the grappler for completion of the removal process from the mold. AtS34, the mold door is closed by the pneumatic door opener, then the dooris relatched. At S36 the mold is held until a full mold has been removedfrom either fill station 1 or 2 allowing placement of the empty moldfrom the extraction station into the now empty position. At S40 theextruded object is sent to the cooling table.

[0062]FIG. 7a, is a flowchart showing the filling process that occurs atstation one (66), and station two (68). At S50 a mold 10, is placed instation one, mold lock then force the mold against the injector to forma seal between the mold and the injector while the mold injection portis opened by the external opener S52, diverter valve then opens S54,allowing the mixture to flow into the mold S56, piston is full forwardagainst the mold door allowing only a small space to be filled by themixture S58, before the mixture begins to force the piston away from themold door S60, piston pushes rod to which is fixedly attached a toothedplate which in turn is engaged to a gear S62, gear turning a connectingrod and a disc S64, disc is restricted by a brake pad through whichforce is applied by a caliper S66, varying the resistance of the brakepad and disc allows the density of the extruded object being molded tobe varied or kept uniform, whichever is desired by the operator S68. Asthe mixture continues to be pumped into the mold the rod continues to beforced out of the mold S70, until the rod engages sensor S72, sensorsignals diverter S74, to move valve from open to station one to closedstation one and from closed station two to open station two, S76, allpreviously recited steps for station one are now repeated at stationtwo, S78, continuing at station one injection port opener closes inputport on mold in station one, S80, mold lock unlocks mold in station one,S82, mold transporter removes mold from station one to cooling bath ofFIG. 7, S84, overflow trimmer is activated to remove mixture thatoverflowed when mold was remove from station one, S86, station one isready for a mold to be moved by mold transporter from extractor stationthree to station one, S88, all steps repeated at station two.

[0063] In FIG. 8, is a flowchart of the air cooling process of anextruded object. FIG. 8, S100, is the equivalent of S32 in FIG. 7. AtS100 the extractor grabs the extruded object. At S102 the extractorapplies force to the extruded object to remove the extruded object fromthe mold, the more force the extractor applies the tighter the jaws ofthe extractor grip the extruded object. At S104 the extractor remains inthe full back position, the extractor table is forced upwards along along side by a pneumatic cylinder mounted under the table. The tablethen pivots on its remaining long side allowing the extruded object tofall off of the extractor table and onto the cooling table below. AtS106 the extractor returns to the full forward position to extract thenext extruded object. At S108 the conveyer moves the extruded objectacross the cooling table while air is circulated across the extrudedobject from under the table. At S110 the extruded object reaches arotation station. Each rotation station is at a predetermined interval.At S112 the object is conveyed over a short precipice causing theextruded object to rotate as it falls from one side to the next side.The object is rotated to allow the object to cool without warping due tothe weight of the extruded object. At S114 the object is moved by theconveyer from one rotation site to the next rotation site if furtherrotation is needed. At S116 conveyer drops object from cooling tableonto texturing table. At S118 texturing conveyermoves extruded objectinto contact with rollers. Rollers are heated by passing a hot fluidthrough them. At S120 heated rollers press textured surface ontoextruded object causing extruded to become textured. As S122 extrudedobject is removed from the system.

[0064] In FIG. 9, 10 and 11, the extractor assembly is shown. FIG. 9 isa side view of the extractor assembly showing extractor 160, mountedabout the extractor table 162, on over head rails 174. Pneumaticcylinder 164 activates to tilt the bed 168 (not shown) of the extractortable about hinge 166, causing the extruded object 10 to slide towardhinge 166. Extruded object 10 further slides to side of bed with hinge166 eventually coming into contact with side door 172, causing side door172 to rotate about hinge 170 allowing extruded object 9 to fall ontocooling table of FIG. 5. FIG. 10 is an end view of the extractorassembly. Extractor 160 is mounted to extractor table 162 using rails174, and mounting brackets 192. Mounting brackets 192 allow extractor160 to move along the long axis of extractor table 162. Threaded fitting194, affixed to extractor 160, is movably affixed to a threaded rod 196.When threaded rod 196 is rotated extractor 160 is caused to move alongthe long axis of extractortable 162. Extractor jaws 188 are attached toarms 184 which in turn rotate on pins 182 attached to extractor assembly160 through a slot 180 into which pins 182 are inserted. Extractor jaws188 are activated, to either engage or release extruded object 9, bypneumatic cylinders 186, causing extractor jaws 188, extractor arms 184and pins 182 to rotate about slot 180. FIG. 10 is a top view of theextractor assembly showing the relation of the extractor jaws 188,pneumatic cylinder attachment pins 190, pneumatic cylinders 186,extractor arms 184, pins 182 and slots 180.

[0065] Referring now to FIG. 12, another very important feature of theinvention is illustrated and described. Railroad cross ties provide akey element of railroad track roadbeds, carrying the load imposed by thetrain wheels on the steel rails and distributing it across the stoneballast and foundation below. Among the forces exerted on the cross tiesis a lateral or centripetal force caused by the train traveling around acurve or rocking side-to-side on a straight section of track. The crossties must resist this force by means of friction against the ballastthat is compacted below and around the ties.

[0066] The traditional wood tie is soft and rough surfaced enough toallow some penetration by the hard and sharp-edged stone ballast. Theresulting adhesion between wood and stone provides resistance todisplacement in service (or in the “single-tie push test” used by therailroad industry to measure the friction), thereby improving thelateral strength of the track structure.

[0067] Steel ties are hollow and are designed to sink down in to theballast to achieve the same result. Concrete ties rely on their heavyweight (over 700 pounds versus 200-270 for wood and composite ties) anda shaped profile to increase friction.

[0068] In the case of plastic and composite ties, the requirement forlateral push stability or increased friction with the ballast is moredifficult to achieve. In the case of profile extruded or continuouslymolded composite ties, the cross-section is constant and the formingprocess generates a smooth surface. It is not possible to producegrooves or impressions perpendicular to the long axis of the tie (i.e.,perpendicular to the direction of extrusion or mold withdrawal). Thesmooth composite tie may not provide sufficient friction to achieve asolid and stable track structure, particularly in curves under heavyloads.

[0069] When the tie contains an appreciable amount of thermoplastic orelastomeric material in its composition, however, the finished tie canbe modified by heat and pressure to provide a solution. The bottomand/or sides of the tie can be textured by applying an embossing patternunder heat and pressure to melt, deform into a desired surface and thenreharden the thermoplastic surfaces of the tie.

[0070] The embossed texture, or pattern, should preferably have certainproperties to provide effective friction with a rock ballast system.

[0071] a. Indentations at least ⅛″ deep.

[0072] b. Indentations should provide surfaces perpendicular to thelongitudinal (long) axis of the tie.

[0073] c. Indentations should be at least ¼″ wide and less than 6″ wide.

[0074] d. Pattern should provide corners or holes to capture and holdindividual pieces of ballast.

[0075] e. Indentations should provide resistance to force across atleast 10% of crosstie surface.

[0076] The texturing can be achieved in three ways;

[0077] 1. Cold rolling or pressing the tie while the surface is stillsoft and malleable.

[0078] 2. Press the pattern into the tie with heated rollers at atemperature sufficient to permanently deform the surface.

[0079] 3. Press the pattern into the tie with heated plates at atemperature sufficient to permanently deform the surface.

[0080] In FIG. 12 includes, in general, a texturer 120, an upper roller122, a pair of roller surfaces, a roller support member 128, a table132, a conveyer 130, a lower roller 134, a heated fluid input 136 and atable support member 126.

[0081] In FIG. 12, table 132 supports extruded object 10. Conveyer 130on the upper surface of table 132 facilitates the movement of theextruded object 10 towards the upper and lower rollers 122 and 134. Hotoil is circulated via hot fluid input 136, through upper roller 122 andlower roller 134 to raise the temperature of upper roller 122 and lowerroller 134. Upper roller 122 and lower roller 134 are oriented relativeto each other such that as the extruded object 10 is passed between therollers causing the two roller surfaces 124 to impress a permanenttexture into the surface of extruded object 10.

[0082] Thus, the apparatus of FIG. 12 achieves the object of havingindentations running perpendicular to the longitudinal axis of theobject, typically a railway crosstie.

[0083] If desired, the pair of rollers 122 and 134 can be replaced witha single roller. Alternatively, the roller or rollers can be replacedwith one or more heated plates (not illustrated) to create the texturedindentations.

1. A member for use as a railroad tie, lumber or other structuralmember, comprising: a mixture of from about 4% to about 55% of athermoplastic polymer, from about 4% to about 55% of a rubbery polymericcomponent; and, from about 4% to about 55% of a reinforcing filler;
 2. Aprocess for forming a member for use as a railroad tie, lumber or otherstructural member, comprising the steps of: mixing, from about 4% toabout 55% of a thermoplastic polymer, from about 4% to about 55% of arubbery polymeric component; and, from about 4% to about 55% of areinforcing filler; injecting said mixture into a mold having at leastone side wall, said mixture at least partially fills said mold aboutsaid side wall, such that said mixture has at least one side surfacealong said side wall and an interior portion; cooling said mixturewhereby said at least one side surface is at least partially hardened;removing said mixture from said mold before said interior portion ofsaid mixture is substantially hardened; placing said mixture within orabout a cooling apparatus; and rotating said mixture about said coolingapparatus whereby said mixture is substantially hardened forming saidmember.
 3. The method of claim 2 wherein said thermoplastic polymer iscomprised of at least one of the materials selected from the group ofmaterials consisting essentially of recycled polyolefins, recycledbucket resin, recycled drum resin, densified film, recycled grocerybags, electric wire coating, and recycled bottle resin or anycombination thereof.
 4. The method of claim 2 wherein said rubberycomponent is comprised of at least one of the materials selected fromthe group of materials consisting essentially of crumb rubber,automotive fluff, tire belt fluff, carpet backing, rubber backing andrecycled circuit boards or any combination thereof.
 5. The method ofclaim 2 wherein said reinforcing filler is comprised of at least one ofthe materials selected from the group of materials consistingessentially of carbon black, fly ash, mica, fiberglass, arregonite,crushed concrete, sand and crushed glass or any combination thereof. 6.The method of claim 2 wherein said materials each comprise from about 4%to 55% of said mixture.
 7. The method of claim 2 wherein saidthermoplastic polymer and rubbery components comprise at least 20% ofsaid mixture.
 8. The method of claim 2 where in said mixture is heatedby frictional and compressive heating of said mixer.
 9. The method ofclaim 2 wherein said mixture is at least partially heated by an externalheat source.
 10. The method of claim 2 wherein said mixture is heatedfrom about 380 degrees to about 440 degrees.
 11. The method of claim 2wherein said mixture is preferably heated from about 400 degrees toabout 420 degrees.
 12. An apparatus comprising: a mold having a sidewall defining an interior portion and an injector port whereby anextrudable material may be injected across said injection port into saidmold, a member located about said mold whereby said member is insealable connection about said interior portion of said side wall, saidmember capable of moving along said interior portion of said side wallwhereby said member may adjustably control a density of said extrudablematerial.
 13. A process for forming a member for use as a railroad tie,lumber or other structural member, comprising the steps of: mixing, fromabout 4% to about 55% of a thermoplastic polymer, from about 4% to about55% of a rubbery polymeric component; and, from about 4% to about 55% ofa reinforcing filler; and injecting said mixture into a mold having atleast one side wall said mixture at least partially fills said moldabout said side wall, such that said mixture has at least one sidesurface along said side wall and an interior portion;
 14. A polymericcomposite comprising: a thermoplastic polymer component comprisingrecycled polyolefin, recycled copolymers thereof or combinationsthereof; a recycled rubbery polymeric component; and, a recycledreinforcing filler component.
 15. A member for use as a railroad tie,lumber or other structural member, comprising: a mixture of from about4% to about 55% of a thermoplastic polymer, from about 4% to about 55%of a rubbery polymeric component; and, from about 4% to about 55% of areinforcing filler; wherein said member has at least one texturedsurface, whereby the said textured surface is applied by a press.
 16. Aprocess for forming a member having a plurality of surfaces, for use asa railroad tie, lumber or other structural member, comprising the stepsof: mixing, from about 4% to about 55% of a thermoplastic polymer, fromabout 4% to about 55% of a rubbery polymeric component; and, from about4% to about 55% of a reinforcing filler; injecting said mixture into amold having at least one side wall, wherein said mixture at leastpartially fills said mold about said side wall, such that said mixturehas at least one side surface along said side wall and an interiorportion; cooling said mixture whereby said at least one side surface isat least partially hardened; removing said mixture from said mold beforesaid interior portion of said mixture is substantially hardened; placingsaid mixture about a cooling apparatus; rotating said mixture about saidcooling apparatus whereby said mixture is substantially hardened formingsaid member; applying a textured surface to at least one surface of saidmember.
 17. A process for forming a member having a plurality ofsurfaces, for use as a railroad tie, lumber or other structural member,comprising the steps of: molding said member from a mixture of: fromabout 4% to about 55% of a thermoplastic polymer, from about 4% to about55% of a rubbery polymeric component; and, from about 4% to about 55% ofa reinforcing filler; and texturing at least one surface of said member.